Nonwoven polymer cloth containing composite spun- or extruded filaments, with e.g. segments of structural polymer and segments of binder, forms perfectly-distributed, ideally- thermally-bonded intersections in product

摘要

The filaments or fibers are unitary, comprising 5-50 wt% of a polymer binder. The cross section exhibits two or more sectors or zones of binder and two or more zones of polymer(s) which will form structural component(s) of the cloth. Following assembly, the cloth is subjected to thermal bonding. Preferred features: The binder comprises 10-30 wt%. It is located predominantly (but not exclusively) in peripheral zones of the composite filaments or fibers. It is visible in at least two separate surface zones. The binder content at the external surface, exceeds the weight content in the composition of the filaments or fibers. Binder and structural polymers are incompatible (do not blend in depth). Following extrusion, the unitary filaments or fibers have a composite, multi-segment structure. They are separated, resulting in two distinct zones of polymer binder, and/or two sectors or distinct zones of polymer(s) to form the filamentary structures of the cloth. The filaments or fibers exhibit an external cylindrical structure, and an internal structure comprising: lamellae, quarter segments with or without a central orifice, satellite structures with or without protuberances, and complementary indentations. External structure of the filaments or fibers is multi-lobed, sectors or zones of binder polymer being preferentially situated at the extremities of these lobes.